operating manual overflow valve / pressure retaining valve

Operating Manual Overflow Valve / Pressure Retaining Valve FLOWsafe (Type 338xx / 339xx)

BA 033800.04 EN

Operating Manual

Overflow Valve / Pressure Retaining Valve FLOWsafe 338xx / 339xx

BA_033800.04_EN Albert Handtmann Armaturenfabrik GmbH & Co. KG 2019-05-07 2 / 16

Overview Page

Table of Contents 2

1. General 3 Proper application, misuse, duty to exercise diligence 3

2. Safety Information 4 3. Delivery and Performance, Storage 5

4. Function and Operation 6 Valve description, valve operation 6 Valve cleaning, pressure setting, component ID 7 Technical data, valve housing executions 8

5. Assembly and Maintenance 9 Safety instructions and warning notices 9 Valve design 11

Assembly / Disassembly 12 Maintenance instructions, troubleshooting 14 Trouble shooting 15

Spare parts list 16

Safekeeping and completeness

• The operating manual is part of the valve delivery package and must be available to authorised personnel at all times.

• It is impermissible to delete chapters from this manual. If the operating manual or pages thereof are missing, they must be replaced immediately.

Updating service

This documentation is not subject to the updating service of Albert Handtmann Armaturenfabrik GmbH & Co. KG. Amendments to this document may be carried out without prior notification. © 2017 Albert Handtmann Armaturenfabrik GmbH & Co. KG Arthur-Handtmann-Str. 11 88400 Biberach/Riss Germany Tel.: +49 7351 342-0 Fax: +49 7351 342-4480 [email protected] www.handtmann.de Any copyrights regarding this technical documentation and any drawings submitted to the receiver in person shall remain at all times with Albert Handtmann Armaturenfabrik GmbH & Co. KG, Biberach, Germany. They must not be copied nor reproduced without prior written authorisation.

Operating Manual



1. General This operating manual must be read and observed by everyone involved with the installation, commissioning, operation and maintenance of the overflow valve / pressure retaining valve.

This operating manual applies to the following valve versions:

Types Equipment FLOWsafe 338xx Valve with manual lifting

Housing version with varying number of connections FLOWsafe 339 xx Valve with pneumatic lifting

Housing version with varying number of connections

Authorized use

• Overflow valves protect a pressurised piping system against impermissible pressure exceedance. The valve is normally closed.

• Pressure retaining valves keep the inlet pressure / primary pressure constant at the valve inlet side. The valve is usually partially open.

• The valve may be used for the intended purpose only. Please pay attention to the specified pressure and temperature range, the flow media and the installation situation.

• This type of valve does not meet the criteria for a safety valve according to the pressure equipment directive. • Applicable and generally recognised safety rules as well as the operating manual instructions must be

followed during assembly and disassembly, in operation and during maintenance.

Misuse

The following are examples of misuse:

• Liquid media different to that envisaged in the operating manual flow through the valve. • Operating conditions other than those specified in the operating manual are present. • The safety information is disregarded during operation, assembly and maintenance.

• Independent modifications or changes to the valve are carried out that restrict safety or functionality.

• Valves are used although they are not functional.

The user's duty to exercise diligence

The user must especially ensure that:

• Installation of the valves is carried out correctly by trained technical staff. • The valves are operated according to their intended purpose and are in a fully functional state. • The statutory requirements for operation, assembly and maintenance are observed. • Only sufficiently qualified and authorised personnel maintain the valves.

Operating Manual



2. Safety Information

Note The following safety information must be considered as additions to the relevant applicable national accident prevention requirements and laws. Please pay attention to the respective rules and regulations in other countries.

Basic safety information Conditions for problem-free functionality of the armature / components: • Proper transport and storage • Installation and commissioning by trained technical staff • Operation and use according to this operating manual • Proper maintenance

Danger – endangerment caused by product-specific and process-specific conditions!

• Disassembling the valve from the piping system without relieving the system pressure first may result in burns, scalding or chemical burns.

• If the valve in a system is operated with acidic or alkaline media, your hands and fingers may suffer chemical burns when disassembling the valve.

• If the valve in a piping system is operated with hot media, the surface temperature of the valve can also reach this value.

• Never place your hand inside the valve housing when the compressed air supply is connected.

• The valve weighs several kilograms.

• The valve contains pretensioned pressure springs. Personal injuries may occur during installation.

o Make sure that the piping system pressure has been relieved.

o Make sure that the piping system has been flushed and emptied.

o Make sure that the piping system has cooled to a value below 50 °C.

o Make sure that the compressed air supply has been disconnected.

o Secure the valve against slipping and falling during transportation.

o Make sure that the pressure spring is secured (valve disk above the lifting nut raised from the seat).

Operating Manual



Caution – danger zone – Malfunction due to incorrect handling!

The valve must be switched off in the case of noticeable malfunctions.

Solve faults immediately.

If the valve is not checked or serviced at regular intervals, it may not work properly.

Check and maintain the valve on a regular basis.

The valve may not work any longer or malfunction considerably if faulty or non-specified parts are installed on the valve.

Only use parts approved by the manufacturer.

The range of application of the valve is intended for specific operating states (pressure, temperature, media).

The valve’s function can be disturbed greatly by different operating conditions.

Make sure of proper application.

3. Delivery and Performance, Storage

• Check the information on the delivery note for correctness and check the delivery for completeness. Later complaints will not be accepted.

• Conduct a visual inspection for transport damage. The forwarding agent must be informed of any visible damages immediately (comment on the waybill).

• Claims due to transport damage not visible right away must be made to the forwarding agent within a week. • Always use suitable lifting gear to unload, transport and store products • Store the delivery in dry rooms and, if possible, in the original packaging to protect it against external

factors.

Operating Manual



338xx 339xx

4. Function and Operation

4.1 Valve Description These overflow valves / pressure retaining valves are intended for application in the beverage and food processing as well as in the chemical-pharmaceutical industries for the indirect process control of a liquid or gas flow. The valve types 338xx / 339xx are characterised by:

• a closed valve design • a solid, welded spherical housing • optimised product chamber separation and sealing • counter pressure compensation via a balance piston / balancer • optimised flow guidance and draining behaviour • hygienically formed product chamber

1 2 3 4 5 6 7 8 9 10

Valve housing Valve connection Valve connection Upper body of valve Pneumatic actuator Valve rod Lifting nut Proximity switch Compressed air connection Leakage bore hole

4.2 Valve Operation

The valves are direct acting, i.e. the force of the medium moves against the spring force. Depending on the installed pressure spring and the setting, there is a certain opening pressure at which the valve starts to open or a closing pressure at which the valve closes.

Caution – damage to components!

In order to ensure that the valve is completely closed, the lifting nut (7) must be tightly countered at the very top of the valve rod.

3

2

4

8 7

9

6

5

1

10

Operating Manual



Due to the integrated balance piston / balancer, the switching function of the valve is not influenced by the pressure level at the outlet side. Besides the manual valve type, there is also a version with pneumatic lifting available. A higher set pressure requires partly an additional lifting device. This type of valve is used, in particular, in hygienic processes when the valve is integrated in a CIP process. This valve series is used for controlled pressure relief, e.g. for overpressure protection in combination with displacement pumps, or for pressure maintenance, e.g. for maintaining pressure in closed circular pipelines.

Installation at the inlet or outlet side of a displacement pump.

If the piping pressure is too high, medium is conducted back in front of the pump.

Installation in a consumer pipe.

Excess medium is conducted back to the receiver tank or to the pump on the inlet side.

Installation in a CIP return pipe.

Pressure maintenance in the tank via continuous regulation of the outflow quantity.

4.3 Valve Cleaning / CIP

Overflow valves / Pressure retaining valves should be cleaned within a defined time period (maintenance plan), especially if the valves are integrated in a bypass pipe. • Manual valves with manual lifting: >> To lift the valve, turn lifting nut against the floor of the housing and add three further clockwise turns >> Clean the seat area above the pipe from bottom to top

• Valves with pneumatic actuator: >> Electrical valve control and lifting via compressed air >> The seat area and the seal are cleaned within an automated CIP process

4.4 Pressure Setting / Component ID

• All the valves are checked ex works and set and secured to the required pressure. The setting is documented in a setting test log.

• The component ID of the overflow valves is structured as follows:

A H – 3 3 8 x x – x x . x x . x . 1 0 / x x x x x x or A H – 3 3 9 x x – x x . x x . x . 1 0 / x x x x x x

Manufacturer

Valve type

Nominal size

Excess set pressure p [bar]

Year of manufacture with consecutive serial no.

3 2

1

Operating Manual



4.5 Technical Data

Product range Materials Stainless steel 1.4404 Seals EPDM, FDA proof Surface (Ra) ≤ 1.6 µm, ≤ 0.8 µm Nominal sizes DN 50, 65, 80 Other parts Materials Stainless steel 1.4307 Surface Polished, matt Production / CIP Flow media Liquids and gases, (non toxic, less aggressive) Set pressure 0 - 10 bar, 0 - 20 bar ∗ Closing pressure Approx. 5 - 10% of the set pressure Temperature 0 - 95 °C / 140 °C Control air (for actuator) 5 - 8 bar, ∅ 6/4

* partly equipped with additional lifting device

338xx 339xx DN

c [mm]

a [mm]

b [mm]

Weight [kg]

a [mm]

b [mm]

Weight [kg]

50 70 536 170 9.5 536 170 12.0

65 85 672 200 16.0 672 200 19.5

80 100 710 230 18.5 710 230 22.0

100 116 750 260 24.5 776 260 36.0

4.6 Valve housing executions

The overflow valve is available with three standard housing executions. Other housing executions are available if desired (2-4 parallel connections or offset by 90°). The broad line in the symbol display indicates the upper line-even.

Order no. manual pneumatic

33801 33901

33802 33902

33804 33904

Exe-cution

Operating Manual



5. Assembly / Disassembly and Maintenance

5.1 Safety Instructions and Warning Notices

Caution – danger zone warning!

Please pay attention to the following prior to installation and commissioning: • Check the valve for visible external and internal damage. • Check the valve housing inside for residues. • Check the current system status (pressure, temperature, medium).

Please pay attention to the following if malfunctions occur and prior to disassembly: • The valve must be switched off and secured against re-use in the case of malfunctions

(disconnect the power and air supply). • Check the current system status (pressure, temperature, medium).

Risk of injuries!

Risk of crushing!

During transportation and assembly / disassembly there is a risk of finger, hand and foot injuries. Never place your hand inside the valve housing when the compressed air supply is connected. When working on the valve, make sure accidental opening and closing of the valve is prevented.

Personal injuries!

The valve contains pretensioned pressure springs. When opening the valve, the upper part of the housing can suddenly spring open. The pressure springs must be mechanically blocked in advance or, if possible, the valve should be controlled pneumatically.

Risk of burns!

If the valve is integrated in a piping system in which the media can reach a temperature of more than 50°C, the surface temperature of the valve can also reach this value.

Risk of scalding, chemical burns!

If the valve is integrated in a piping system that has not been fully emptied or is still pressurised, there is a risk of scalding and other personal injuries.

Operating Manual



Caution – functional impairment or material damage!

Installation instructions: • Install valves in the piping system upright and free of tension. • Valves for welding in must be disassembled first. The housing is

then welded into the piping system free of tension. • Remove welding residue from the piping system. • The welding work (TIG, welding gas) should only be carried out by qualified welders (EN

287-1). • There must be sufficient free space around the installed valve for assembly and

maintenance tasks later on.


Assembly instructions: • Only disassemble valves after the pressure spring has been mechanically blocked. • Do not damage the valve insert, sliding surfaces or sealing surfaces.

Only use suitable tools and tensioning devices. • Only use suitable and accepted spare parts from the manufacturer. • Slightly grease seals and insert them evenly into the groove.

(only use grease approved for the field of food processing) • Bolts, slightly grease threads. Tighten parts evenly.

Operating Manual



5.2 Valve Design

1 Valve housing 2 Upper part 3 Upper part attachment

4 Valve inlet 5 Valve outlet 6 Valve piston rod

7 Valve disk 8 Pressure spring 9 Spring seat

10 Spring pressure piece 11 Pressure disk 12 Pneumatic actuator

13 Lifting piston 14 Guide insert 15 Cylinder sleeve

16 Housing flange 17 Compressed air connection 18 Counter nut

19 Locking washer 20 Lifting nut 21 Cap nut

22 Valve disk coupling

10 Valve disk O-ring seal 20 Housing O-ring seal

30 Valve piston form seal 40 Valve rod O-ring seal 50 Lifting piston O-ring seal

60 Lifting piston O-ring seal 70 Cylinder sleeve O-ring seal 37 Housing flange O-ring seal 38 Housing flange O-ring seal

Type 338xx, DN 50 - 80

Only type 339xx, DN 100

1

3

2

10

18

4

5 6

9

9

8

8

11

19

14

13

15

17

20

21

22

7

40

20

30

50 60

70

10

14

16

20

60

37 38

13 12

1

3 2

10

18

4

5 6

7

9

9

8

8

11

14

21

20

22

20

30

40

10

Type 339xx, DN 50 -80

Operating Manual



5.3 Disassembly / Assembly

Disassembly of manual valves

Proximity switch

Upper part attachment

Spacing Lifting nut

Counter nut

Cap nut

Valve piston form seal

Valve rod O-ring seal

A B

F

Remove the cap nut, turn lifting nut against the upper part attachment, add two further turns

Replace seals at the guide insert

Spring pressure piece

Spring pressure disk

Valve rod

C D

Remove upper part via the valve rod, remove the spring seat and pressure springs

Valve piston rod

G

Unscrew bolts and lifting nut alternately, repeat until upper part makes contact with the bolt head

Unscrew the valve disk from the piston (adhesive joint – heat up in advance!), replace seal

Guide insert

Valve disk

E

Extract the valve rod, remove guide insert from the valve rod

Valve housing

Upper part

Bolts

Valve insert

Upper part

Pressure spring

Valve piston rod Housing O-ring seal

Guides

Valve disk

Valve disk O-ring seal


Lifting nut

Upper part

Bolts

Pressure spring has been relieved, remove lifting nut and bolts

Operating Manual



Disassembly of pneumatic valves

Valve rod O-ring seal

G

Replace seals at the guide insert

Valve piston rod

H

Unscrew valve disk from the piston (adhesive joint – heat up in advance!), replace seal

Guide insert

Valve disk

E

Extract valve rod, remove lifting piston and guide insert from the valve rod

Valve piston rod

Housing O-ring

Guides

Valve disk

Valve disk O-ring seal

Lifting piston

Proximity switch

Upper part

Spacing Lifting nut

Counter nut

Cap nut

Lifting piston O-ring seal

A B


C D

Pressure spring has been relieved, remove lifting nut and bolts

Valve housing

Upper part

Bolts

Valve insert

Lifting nut

Guide

Upper part

F

Replace seals at the lifting piston

Lifting piston O-ring seal

Replace seal at the cylinder sleeve or the housing flange seal

Cylinder sleeve O-ring seal

Remove the cap nut, turn lifting nut against the upper part attachment, add two further turns

Unscrew bolts and lifting nut alternately, repeat until upper part makes contact with the bolt head

Valve piston form seal

Spring pressure piece

Spring pressure disk

Valve rod

Upper part

Pressure spring

Bolts

Remove upper part via the valve rod, remove the spring seat and pressure springs

Operating Manual



5.4 Maintenance Instructions


Inspection and maintenance intervals:

• Visual inspections must be carried out continuously every 2 - 4 weeks. >> Check electrical and pneumatic supplies >> Check for leaks, perform a function test of the valves

• To ensure that the valve is ready for operation and functionally reliable, it should be checked every six months within the scope of the general internal maintenance procedure.

>> The maintenance intervals depend on the operating conditions and must be determined by the plant operator.

• If protection devices were attached for maintenance or supply and exhaust lines to the valve blocked, the protection devices / line blockings must be disassembled.

• Ensure that a function check is always performed on the valve following maintenance work.

Maintenance intervals

The maintenance intervals are geared to the operating conditions, such as switching frequency, kind of media, process temperature, temperature change, process pressure, etc. For this reason the maintenance cycles should be determined by the user.

It is recommended, however, that the seals always be checked every 6 months if they are operated at high switching frequencies and high media temperatures. A full inspection should be carried out every 12 months.

CIP cleaning

The valve and the sealing material in the product-affected area are designed for standard CIP operation.

The following are to be considered as standard conditions:

• CIP media on the basis of commercially available caustic-acid components with given chemical resistance to EPDM sealing material. Consultation should be carried out with the valve manufacturer for different kinds of media.

• Cleaning additives in the concentration range of 2-3%. • Temperatures for cleaning media in the range of 30-75°C or hot water to 90°C. • Pressure range for housing cleaning 2-8 bar. • Flow velocity 2-4 m/s.

Operating Manual



5.5 Troubleshooting

• All faults must be checked and repaired immediately by qualified personnel. • When carrying out the necessary work, keep strictly to the safety information.

Malfunction Possible causes Measures

Valve does not open (pneumatic)

• Valve seat jammed

• Pressure insufficient for opening

• Lifting / Opening process is blocked

• Compressed air supply insufficient

• Solenoid valve or electrical control has been disturbed

• Lift the valve manually and clean the valve seat

• Check the pressure setting

• Check free movement of the valve rod (lift the valve manually)

• Compressed air at least 5 bar, check the compressed air hose

• Check the solenoid valve

Valve does not close (pneumatic)

• Lifting nut is screwed against the housing

• Solid body in the valve seat • Seal defective • The actuator spring is blocked

or broken • Pressure bleeding defective

• Screw the lifting nut upwards

• Clean the valve housing and seat • Replace the seal • Repair actuator, only use

spare springs from the manufacturer • Check the solenoid valve

Leakage outlet (housing bore hole)

• Sealing ring defective

• Disassemble housing • Replace sealing ring

Operating Manual



5.6 Spare Parts List

33801 DN 50 – 80

33901 DN 50 - 80 DN 33801 33901

50 033801.00050LE 033901.00050LE

65 033801.00065LE 033901.00065LE

80 033801.00080LE 033901.00080LE

Seal change

Please note the following points:

• Use a suitable tool (dig hook) to remove the seals

• The sealing grooves should be cleaned thoroughly before installing the new seals. • Slightly grease the seals (only use grease approved for the field of food processing) • Insert seals evenly into the sealing grooves • Secure valve disk with Weinconlock after replacing the O-ring (adhesive connection)

operating manual overflow valve / pressure retaining valve

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